Containerized transportable building structure and method of assembly

ABSTRACT

Method and apparatus for transforming a plurality of standard-size shipping containers into a finished multi-level building structure of a scale to accommodate humans. Each of the illustrated shipping containers has an open generally rectangular center structural frame which supports panels to provide exterior base, end and top walls. A pair of movable side walls, each having a structural frame and wall panel, are connected to the center frame to complete the enclosure. The containers hold wall and roof sections. Initially the containers are stacked atop one another with their base walls at the bottom. Then, starting at the lowermost container, the side walls, which are hingedly connected along their bottom edges to the center frame, are opened by being pivoted outwardly, downwardly to provide extended floor portions that are in general horizontal alignment with the associated base wall. Then support structures or members are secured to that extended floor portions to provide support for the extended floor portions of the next higher level. Next, the moveable side walls of the next higher container are similarly opened and secured to the support members so as to generally vertically align with the extended floor portions below them. This continues until all the stacked containers have been opened. Finally, wall and roof panels stored in the containers are removed and installed.

BACKGROUND OF THE INVENTION

The present invention generally relates to transportable multi-levelbuilding structures. More particularly, the illustrated apparatus is inthe form of a multi-level building structure of a scale which willaccommodate human beings. The structure is assembled from a plurality ofspecially designed transformable container units that simulate and serveas shipping containers meeting ISO specifications. It is capable ofbeing opened and assembled on-site with minimal complexity and manhours.

There exist many situations where temporary or transportable housing isneeded. For example, during natural disasters people are often displacefrom their homes. During times of military conflict, barracks, MASH andother buildings are required, often in remote locations. Othersituations include temporary offices, such as on-site constructionoffices and the like.

In the past, tents have widely been used as temporary shelter duringnatural disasters. However, it will be readily understood that thesestructures are incapable of suitably housing individuals or families fora prolonged period of time. Furthermore, tents do not provide thecomforts of living, particularly in adverse weather conditions.

In other instances, pre-fabricated self-contained buildings, oftenreferred to as mobile homes, are used. While such mobile homes providethe comfort of living and allow prolonged use, they are very costly. Inaddition, although such mobile homes are often transportable to a sitevia a trailer attached to a semi-truck, such mobile homes are oftenunwieldy and difficult to transport. Moreover, such mobile homes aretypically not able to be conveniently transported by rail, air, orships. As the primary means of transporting such mobile homes is viatrailer truck, the width of such mobile homes is limited by the spaceavailable on a road, typically eight feet. Of course, mobile homes canbe provided as “double-wide” units, wherein one-half of the unit istransported by separate trailer trucks. However, this increases thecomplexity and cost of transporting the mobile home unit.

Accordingly, there is a continuing need for buildings which can betransported via various traditional means in a convenient fashion. Suchbuildings should be capable of being assembled with minimal machineryand man hours. Preferably, such building units should be capable ofbeing much larger that their containerized kit. The present inventionfulfills these needs and provides other related advantages.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate the invention. In such drawings:

FIGS. 1-7 schematically illustrate the assembly of a two-level buildingfrom a pair of like shipping containers in accordance with a presentlypreferred embodiment of the invention;

FIG. 8 schematically illustrates an alternative presently preferredembodiment of the invention.

FIG. 9 schematically illustrates four shipping containers stacked toprovide a four level building structure.

DETAILED DESCRIPTION OF THE DISCLOSURE

FIGS. 1 through 7 schematically illustrate utilizing a plurality oflike, stackable, shipping containers to construct a multi-level buildingstructure. This apparatus and the method of construction/assemblyrepresent a presently preferred embodiment of the invention.

FIG. 1 illustrates a pair the shipping containers 10 stacked, one on topof the other, at the construction site. They may be brought to the siteby truck or the like, and have been stacked by the use of a suitablelifter/mover such as a crane.

In general, each of the illustrated shipping containers 10 a, 10 b has agenerally rectangular structural center frame 12. More particularly,each illustrated center frame 12 includes a base 14 having a pair oflong side members 16 and a pair of short end members 18. The frame 12also includes a top 20 having a pair of long side members 22 and a pairof short end members 24. There are also upright structural frame cornermembers 26 that connect the four corners the frame base 14 to therespective four corners of the frame top 20, and provide support for theframe top. Further, as shown in FIG. 2, there is an upright structuralframe center member 28 that extends between each base long side member16 and the adjacent top long side member 22 midway between the ends ofthe container to provide added structural support. The frame top 20 maybe reinforced by a horizontal structural frame center member 30 (shownonly for the upper stacked container 10 b) that extends between the toplong side members 22 generally midway between ends of the container.Similarly, the frame base 14 may be reinforced by a horizontalstructural frame center member (not shown) that extends between the baselong side members 16 generally midway between ends of the container.These horizontal center frame members 30 are generally aligned with theupright frame center members 28. The illustrated frame may beconstructed of various suitable materials such as metal, wood, or rigidhigh-strength plastic.

Suitable wall sections or panels are secured by usual means to portionsof the center frame 12 to provide exterior walls for the associatedclosed shipping container 10. The illustrated wall sections or panelsmay be constructed of suitable materials which are desirable waylightweight yet durable. By way of example, the wall sections or panelsmay be made from wood, plywood, plastic in foam or other form, etc.

In the illustrated container, there are base sections or panels 38 thatprovide the exterior base or bottom wall 48, end wall sections or panels40 that provide the exterior end walls 49, and top sections or panels 44that provide the exterior top wall 51 (shown only for the uppercontainer 10 b). The center frame 12 together with the base wall 48, theend walls 49 and the top wall 51 define the center portion of thebuilding structure. Extending or enlarging portions of the buildingstructure will be described below.

As seen best in FIG. 2, each of the containers 10 a, 10 b also has apair of rectangular side frame sections 32. Each of the illustratedrectangular side frame sections 32 has a pair of short end members 34and a pair of long members 36. Side wall sections or panels 42 aresecured by usual means to the sidewall frame sections 32 to provideexterior side walls 46. When the side walls 46 are in the close shippingposition shown in FIG. 1, the side walls are generally upright. Thus,for each sidewall 46, one of the long frame members 36 a of its sideframe section 32 is at the top and the other of the long frame members36 b is at the bottom. Each long frame member 36 b at the bottom ishinged to the adjacent long side member 16 of the frame center base 14so that the side wall or floor extender section 46 can bepivoted/lowered to the opened, extended position shown in FIG. 2. Eachside wall or floor extender section or wall 46 thus forms an extendedfloor portion.

FIG. 2 illustrates both side walls 46 in the opened, extended position.In this position, the side walls or floor extender portions 46 aregenerally horizontally aligned with the center base 48. Sections 46provide extended floor portions that combine with the base 48 to form anenlarged generally flat horizontal floor. During shipment, the sidewalls 46 are releasably, but securely, fastened in the upright, closeposition by suitable means such as releasible clamps (not shown).

The base, end, and top exterior walls 48, 49 and 51 remain in positionwhen the shipping container is opened and assembled, as shown in FIG. 2,to provide, respectively, the floor, the end walls and the top orceiling for the level provided by that shipping container. The centerframe 12 of each container provides structural support for its level, aswell as for levels above it.

As noted above, during assembly, the side walls or floor extendersections 46, which are each comprised of their side wall panels 38 andtheir side frame section 32, are released and pivoted to their opened,extended positions as shown in FIG. 2. The base 48, which is comprisedof the frame center base 14 and the base panels 38, and the openedsidewalls 46, rests upon a suitable supporting surface, which may be theground or a foundation, in a generally level horizontal position. Whenthe side walls 46 are opened, they are no longer contributing to thestructural support of the center portion of the building structure.However, it will be noted that that center portion of the buildingstructure remains well supported by the center frame, particularly theupright frame members 26, 28 which in turn are supported by the framecenter base 14.

When the side walls 46 are lowered, the sides of its container arethereby fully opened to provide easy access to the interior of thecontainer. Each container holds additional components for theconstruction of the final building structure as will be described below.

FIG. 3 illustrates the next step in the assembly of the illustratedmultilevel building structure. Upright structural support posts ormembers 50 are positioned and secured at each outer corner of each openside wall 46 and at the outer edge of each side wall intermediate itsends. These upright structural posts 50 are secured to the frame members34, 36 of the side wall frame sections 32 by suitable means such asflanges secured by nuts and bolts (not shown).

Next, as shown in FIG. 4, the side walls or floor extender sections 46 bfor the second or upper shipping container 10 b are released and pivotedto their opened, extended positions generally horizontally aligned withthe base 48 b of that upper container. As with the lower-level, each ofthe side walls 46 b for the upper level forms an extended floor portionthat serves to provide an enlarged floor for that upper level. They alsoprovide enlarged ceiling portions for the lower level that are generallycoextensive and vertically aligned or overlying the extended floorportions of the lower level floor created by its open extended sidewalls 46. Upright posts 50b are secured to the frame of the upper-levelopen side walls 46 b by suitable connection means such as flanges, nutsand bolts (not shown).

As shown in FIG. 4, at this stage of assembly the contents of the twocontainers remain in place aside from the lowering and extending of theside walls. If a third level were to be added to this buildingstructure, a like third shipping container it would have been initiallystacked atop the second container. In such case, upright structuralsupport posts or members 50 as were used at the lowest level would beattached to the frame/floor of the second level and the side walls 46 ofthe third container would be released and lowered so as to extend overthose second level posts 50. If there were a fourth or additionallevels, the assembly process would proceed as just noted for the thirdlevel. FIG. 9 illustrates four stacked containers.

FIG. 5 illustrates the next step in the assembly/construction. Wallpanels or sections 52 packed in the lower level are removed, positionedand attached to complete the side walls for the lower level of thebuilding structure. These panels 52 extend around the extended areas atthe lower level provided by the outwardly extending base or floorsections formed by the lowered side walls 46 and 46 b. The attachment ofthe side wall panels 52 may be accomplished by various meanings known inthe construction trades. For example, a tongue-and-groove typeconnection between the panel edge and the adjacent frame member may beused.

If there were three or more levels, the assembly of the side wall panels52 would preferably await opening of all of the containers. Thisfacilitates ready access to the various containers for components,tools, etc. as they are needed for the assembly of the wall panels.

Thus, the assembled lower level of the building structure comprises theoriginal rectangular center portion provided by and having the size ofthe shipping container 10, and an enlarging or extended side portion ateach side of the center portion. Each of the side portions is defined bythe upper and lower level opened, extended side walls or floor extendersections 46, 46 b which form the extended floor portions at that side ofthe structure, and the associated additional side wall panels 52.

Alternatively, as illustrated in FIG. 8, in lieu of the upright posts 50and the separate side wall panels 52, reinforced sidewall panels 52 cwith integrated frame members (not shown) may be utilized. In thisalternate embodiment, before the upper side walls 46 b are lowered, thepanels 52 c would be secured in place. Then the upper side walls 46 bwould be lowered and secured to the panels 52 c.

FIG. 6 illustrates the next step which involves additional, individualside wall panels 52 b that were packed in the upper shipping container10 b. These panels 52 b are removed, positioned and secured to the upperlevel side wall frame section 32 b and to the upper level uprightmembers 26 b, 28 b, to provide the upright exterior and interior wallsfor the extension portions of the upper level. Since there is not athird level provided in this embodiment, there are no extended top wallsprovided by opened side walls 46 for these side wall panels 52 b toattach to. Since there is no higher third level, the panels 52 b needonly support a roof and not another level. This also obviates the needfor structural support members at the upper second level.

As shown in FIG. 7, the upper edges of these additional sidewall panels52 b are secured to roof panels 54 to provide further rigidity andstructure to both the side wall panels 52 b and the roof panels 54. Itwill be noted that, in the illustrated embodiment, as shown in FIG. 7,the roof over each extended portion is angled or inclined. Toaccommodate this incline, certain side wall panels 52 b′ located at theends of the structure have inclined upper edges 53. In addition, shortupright roof support panels 55 are provided and secured along each sidemember 22 b of frame top 20 b of the upper level. These panels 55connect to and support the elevated inward sides of the inclined roofpanels 54.

As also illustrated in FIG. 7, additional structure providing a stairway56 to the upper-level and a landing 58 at upper-level may be secured tothe outside of the assembled building structure. One or more doorways 60are provided in certain of the upper-level side wall panels 52 a leadingfrom the upper end of the stairway 56 and/or the landing 58 into theinterior of the upper-level.

Desirably the apparatus may be constructed and arranged so that it canbe readily disassembled and packed into the shipping container forstorage and/or shipment to another site.

The illustrated shipping containers or enclosures desirably meets theISO approved container specifications. As such, the container is 8′6″tall and 8′ wide at its exterior, and is either 20 feet or 40 feet inlength so as to meet the standard requirements. The containers can thusbe transported and stored as ISO approved shipping containers.

Thus, those skilled in the art, will appreciate that the presentinvention provides ideal temporary or semi-permanent building use inalmost any application, including disaster relief, portable housing,mobile offices, large remote projects, military, decontaminationscenters, emergency hospitals, migrant farm housing and classrooms. Afterthe unit has fulfilled its need, it can be disassembled in the samemanner it was assembled and closed back up into its original containers.These can be stored without need to worry about vandalism or weathering,or it can be transported to its next destination and used once again.Although the shell of the unit remains virtually unchanged, differentmaterials may be used to adapt to user's needs and the product may becustomized depending upon the ultimate use. The present inventionincludes the benefits of being self-contained, easily transported,re-deployable, and easily stored and secured. Due to the kit-nature ofthe building unit, the parts may be fully replaceable so as to preventthe need to replace the entire unit.

Although an embodiment has been described in detail for purposes ofillustration, various modifications may be made without departing fromthe scope and spirit of the invention.

1. A method of transforming a plurality of shipping containers into anassembled multi-level building structure of a scale to accommodate humanbeings, such containers each being in the form of an enclosure having anexternal base wall and at least one floor extender section moveablymounted on the container, said method comprising: a) stacking two ofsaid shipping containers atop one another upon a supporting surface,with their base walls lowermost, b) moving at least one floor extendersection of the lowermost container, that will provide the lowermostfirst level of the building structure, into a generally horizontalextended position that is generally horizontally aligned with the basewall of that container and provides an extended floor portion for thatlowermost first level, c) mounting first level support members on saidextended floor portion to provide support for the extended floor portionof the next higher second level, and d) then moving at least one floorextender section of the next higher container, that will provide thenext higher second level of the building structure, into a generallyhorizontal extended position where it is generally horizontally alignedwith the base wall of that second level container, it provides anextended floor portion for that second level, which is also a ceilingfor the lowermost first level, it is generally vertically aligned withsaid next lower first level extended floor portion, and it is supportedby said first level support members.
 2. The method of claim 1 for addinga third level to the building structure, said method comprising thefurther steps of: e) stacking a third one of said shipping containersatop said second level container, f) mounting second level supportmembers on said extended floor portion of said second level to providesupport for the extended floor portion of the next higher third level,g) moving at least one floor extender section of the next highercontainer, that will provide the third level of the building structure,into a generally horizontal extended position where it is generallyhorizontally aligned with the base wall of the third level container andit provides an extended floor portion for the third level, it isgenerally vertically aligned with the extended floor portion of the nextlower second container, and it is supported by said second level supportmembers.
 3. The method of claim 2 for adding a fourth level to thebuilding structure, said method comprising the further steps of: h)stacking a fourth one of said shipping containers atop said third levelcontainer, i) mounting third level support members on said extendedfloor portion of said third level to provide support for the extendedfloor portion of the next higher fourth level, and j) moving at leastone floor extender section of the next higher container, that willprovide the fourth level of the building structure, into a generallyhorizontal extended position where it is generally horizontally alignedwith the base wall of that fourth level container, it provides anextended floor portion for that fourth level, it is generally verticallyaligned with the extended floor portion of next lowest third levelcontainer, and it is supported by said third level support members. 4.The method of claim 3 for adding additional levels to the buildingstructure, said method comprising the further steps of: k) stacking oneor more additional of said shipping containers atop said fourth levelcontainer, and l) for each added level, starting with the lowest addedlevel, mounting added level support members on the extended floorportion of the next lowest level container to provide support for theextended floor portion of that next added level container, moving atleast one floor extender section of that added level container, thatwill provide the next higher level of the building structure, into agenerally horizontal extended position where it is generallyhorizontally aligned with the base wall of that added level container,it provides an extended floor portion for that added level container, itis generally vertically aligned with the extended floor portion of thenext lowest level, and it is supported by said added level supportmembers,
 5. The method of claim 1 wherein: said containers contain sidewalls panels and roof panels to provide exterior side walls and a rooffor the extended portion of the assembled building structure, the addedsteps of: positioning and securing the side wall panels in generallyupright positions between said extended floor portions to provide sidewalls for the extended portion, and positioning and securing roofsections to the side walls panels of the uppermost level to provide aroof for extended portion of the building structure.
 6. The method ofclaim 5 wherein the upright side wall panels are positioned and securedat the first level only after the floor extender panels of the nexthigher second level has been moved into opened, extended position. 7.The method of claim 1 wherein the upright side wall panels arepositioned and secured at the first level before the floor extendersection of the next higher second level has been moved to its opened,extended position.
 8. The method of claim 2 wherein the containerscontain side wall panels and such side wall panels are positioned andsecured at the first and second levels only after the floor extendersections for the second and third levels have both been moved to theiropened, extended positions.
 9. The method of claim 3 wherein thecontainers contain side wall panels and such side wall panels arepositioned and secured at the first, second, and third levels only afterthe floor extender sections for second, third and fourth levels have allbeen moved to their opened, extended positions.
 10. The method of claim1 wherein the components are releasably connected for subsequentdisassembly and repackaging in the containers.
 11. Apparatus in the formof shippable building containers transformable to construct amulti-level building structures of a scale suitable to accommodate humanbeings, said apparatus comprising: a) a plurality of shippable buildingcontainers for being shipped to a desired location, opened at thatlocation, and assembled to construct a multi-level building structure ofa scale suitable to accommodate human beings, each of said buildingcontainers comprising generally rectangular box-like open structuralframe which supports panels to provide exterior walls that combine toform an enclosure, each of said containers providing a level for thebuilding structure, one of said exterior walls for each container beinga generally flat exterior base wall, at least one other of said exteriorwalls for each container being a movable floor extender wall movablyconnected to its container and movable to an extended generallyhorizontal position where it is generally horizontally aligned with itsbase wall and provides an extended floor portion for that level, and itis generally vertically aligned with extended floor portions of otherlevels, and b) support members mountable on said extended floor portionsat at least all levels except the uppermost level to provide support forthe vertically aligned extended floor portions of the levels above it.12. The apparatus of claim 11 wherein said support members at each levelcomprise a set of elongated poles each adapted to fixedly connect ateither end to one of said extended floor portions.
 13. The apparatus ofclaim 11 wherein said building containers also comprise wall sectionsconnectable at the time of assembly to said extended floor portions toprovide generally upright outside walls for extended portions of saidassembled building structure.
 14. The apparatus of claim 11 wherein saidbuilding containers also comprise roof sections connectable at the timeof assembly to said extended floor portions to provide a roof forextended portions of said assembled building structure.
 15. Theapparatus of claim 11 wherein said building containers are reusable,said base wall sections, said upright wall sections, and said roofsections being configured and arranged to be releasably connected to oneanother at the time of assembly.
 16. The apparatus of claim 11 whereinthere are at least two movable floor extender walls on each container.